Eifs structures, methods of manufacturing and compositions for use in eifs cladding for reducing bird-related exterior wall damage

ABSTRACT

An enhanced base coat for an exterior insulation finishing system (EIFS) includes a bird repellent dispersed throughout a base material. A preferred bird repellent includes methyl anthranilate. EIFS claddings of the present invention include insulation boards mounted to a substrate with adhesive, the enhanced base coat applied to the exposed surface of the mounted insulation boards, a first mesh and an optional second mesh embedded in the enhanced base coat, and a finishing coat applied to the enhanced base coat in which the mesh(es) are embedded.

FIELD OF THE INVENTION

The present invention relates to techniques for reducing damage to exterior insulation finishing system (EIFS) structures caused by birds. More particularly, the present invention relates to compositions to be used in manufacture of EIFS structures, methods of building EIFS structures and EIFS structures to avoid substantial damage to such structures from pecking, drumming or drilling by birds.

BACKGROUND OF THE INVENTION

Exterior insulation finishing system (EIFS) structures are exterior building wall cladding systems comprising an integrated system of multiple layers. EIFS is distinct from traditional stucco systems which utilize a mixture of Portland cement, sand and water, and are dense but substantially non-insulating. In contrast, EIFS creates a weather resistant, seamless, insulated finish to a residence or commercial building. In combination with windows, flashing and sealants, EIFS resists moisture penetration. The outer layer may be virtually any color and the multiple-layer structure of EIFS allows for building up and variable thicknesses, thereby creating distinct architectural features such as quoins and other shapes, so that buildings clad with EIFS can have exceptional aesthetics. EIFS requires very little maintenance.

Referring to FIG. 1, a conventional EIFS structure 10 is shown, installed on a substrate 11. Substrate 11 constitutes the outer surface of the building prior to cladding with the EIFS. Substrate 11 typically is an exterior grade sheathing such as glass mat faced gypsum, water-resistant exterior fiber-reinforced gypsum, plywood, OSB (oriented strand board) or prepared masonry or concrete. EIFS structure 10 comprises adhesive 12, insulation board 13, optional mechanical fasteners 14, base coat 15, reinforcing mesh 16 and finish coat 17.

Adhesive 12 is chosen so as to permanently adhere to both substrate 11 and insulation board 13. One adhesive 12 widely used is a 100% polymer-based product field-mixed 1:1 by weight with Portland cement and marketed as Sto® Primer/Adhesive by Sto Corporation, Atlanta, Ga. Typically, ribbons of adhesive 12 are applied with a U-notched towel to insulation board 13. Alternatively, adhesive 12 may be applied to substrate 11.

Insulation board 13 is typically an expanded polystyrene (EPS) board in a 2′×4′ panel from ¾″ to 3″ thick, with the 1½″ thick panels widely used. Once adhesive 12 is applied, insulation board 13 is pressed onto substrate 11, with adhesive 12 sandwiched therebetween. Adjacent insulation board 13 panels are butted tightly together, with horizontal rows of insulation board 13 panels offset so that vertical joints are staggered.

Optional mechanical fasteners 14 each comprising a washer-like plastic component 18 through which a screw 19 is inserted, are mounted though insulation board 13 and into substrate 11.

Prior to application of base coat 15 to the exposed surface of mounted insulation board 13, the exposed surface is rasped to level it and remove excess or irregular material. Thereafter, base coat 15 is applied to the rasped surface, typically with a trowel, to a thickness of from ⅛″ to ¼″, commonly ⅛″. Base coat 15 may be a polymer based product mixed with Portland cement, and may be the same material as adhesive 12. Alternatively, base coat 15 may be an acrylic-based product, optionally fiber-reinforced, and mixed with Portland cement. Other alternative base coats include the following: water-based tintable acrylic base coat applied without the addition of Portland cement; dry blend, polymer-based adhesive and base coat which is field mixed; high-performance, fiber-reinforced dry blend adhesive and base coat specifically formulated for systems; sprayable, dry blend, polymer-modified adhesive and base coat for use with Dryvit™ systems; fast setting, polymer-modified, fiber-reinforced, cement-based, dry blend adhesive and base coat for use with during colder weather; and fast setting, polymer-modified, fiber-reinforced, cement-based, dry blend adhesive and base coat.

Reinforcing mesh 16 is then embedded in wet base coat 15 and base coat 15 is smoothed over with the trowel so that no reinforcing mesh 16 remains visible. Reinforcing mesh 16 is available in different weights and types to meet different requirements for strength and impact resistance. Exemplary meshes under the Finestone® trademark and available through BASF Wall Systems of Jacksonville, Fla., are categorized as follows: Standard Reinforcing Mesh having a Leno weave, weight of 4 oz/yd², and fabric count of 6×5; Intermediate 6 Reinforcing Mesh having a Leno weave, weight of 5.6 oz/yd², and fabric count of 6×5; Intermediate 12 Reinforcing Mesh having a Leno weave, weight of 11 oz/yd², and fabric count of 16×12; Strong 15 Reinforcing Mesh having a Hurl Leno weave, weight of 15 oz/yd², and fabric count of 4×4; and Hi-impact 20 Reinforcing Mesh having a Hurl Leno weave, weight of 20 oz/yd², and fabric count of 4×3.

The base coat 22 is then allowed to thoroughly dry. Once dry, base coat 15 containing embedded reinforcing mesh 16 is then covered with finish coat 17 in a continuous application by trowel or spraying. Finish coat 17 may be textured and made from any of the following exemplary materials: an acrylic-based coating resulting in a standard DPR (Dirt Pickup Resistance) finish; a lightweight, premixed 100 percent acrylic-based coating; a water-based, acrylic coating with integral color and texture, formulated with PMR chemistry; or an elastomeric DPR, and water-based acrylic coating with integral color and texture. Finish coat 17 is typically 1/16″ thick, although thicknesses of from 1/32″ to 3/32″ are not uncommon.

While buildings clad with EIFS and installed as described above have the substantial benefits previously mentioned, they can be vulnerable to damage from birds, in particular from woodpeckers, flickers and other birds which exhibit repetitive drilling, pecking or drumming behavior. In the western United States, flickers in particular are known to peck holes in EIFS walls when looking for insects to eat and building nests.

In particular, Northern and Red-Shafted Flickers, which inhabit the United States can cause problems in residential and commercial buildings. Flickers tend to return to the same nesting hole year after year, with decaying trees and tall desert cacti home to flickers in the native environments. The decaying trees and cacti have soft fibers, similar to foam board, which can easily be pecked out by flickers. In addition, the decaying trees and cacti retain moisture that attracts ants, termites and other insects that bore into the fibers, thereby providing food for birds and making the structures more easily inhabited by the birds. The birds are further attracted to these decaying trees and cacti by the formic acid and vibrations produced by the resident insects. In pecking for insects, the birds have learned that the decaying trees and tall desert cacti have a hollow sound, and the birds' drumming is not only useful to hollow out a hole in which to live, the sound which is transmitted is used for mate attraction.

EIFS cladding has much of the same qualities as cacti as described above and is believed attractive to flickers and other birds for much the same reasons. Drumming by such birds creates a similar hollow sound to the sound produced when drumming or drilling in cacti, and a nesting hole is easily created in the EIFS cladding. However, the holes in EIFS created by these birds are not only unsightly, they create a point of entry to the building for moisture, allergens, dirt and animals. Patching does not solve these problems, as the birds are not deterred from returning to the same location in the future or drilling elsewhere on the same building.

However, flickers are a protected species and between March 1 and July 1, flicker nests should not be disturbed. Accordingly, it is important to prevent flickers from creating holes for nests in buildings because once the flicker is established in the building hole, during the period from March 1 to July 1, problems created by the hole resulting from access to the building structure by moisture, insects and animals, cannot be readily solved.

There is at least one bird repellent which has been marketed as one which can be applied to an existing structure. Specifically, Bird-X Inc. of Chicago, Ill., has registered a bird repellent concentrate for commercial and home use for turf and structures under the name Fruitshield-Goosechase, which contains by weight 26.4% methyl anthranilate as an active ingredient. The Fruitshield-Goosechase label describes application for structures as involving 1 part of the concentrate mixed with 1 part water and applied with a hand sprayer. However, this application technique to EIFS cladding does not always completely deter flickers from drilling holes into EIFS, it being postulated that the long beak of the flickers quickly passes through the outer facing surface of the EIFS to which the methyl anthranilate has been applied, and so is not sufficiently deterred by the irritating smell or dust of the methyl anthranilate to prevent creating of nesting holes in the insulation boards of the EIFS cladding.

Thus, there remains a need for modified EIFS structures and installation methods which will significantly minimize damage by birds to EIFS claddings.

SUMMARY OF THE INVENTION

EIFS claddings of the present invention most preferably include (a) insulation boards mounted to a substrate with adhesive, (b) an enhanced base coat applied to the exposed surface of the mounted insulation boards, (c) a first mesh, and optionally a second mesh embedded in the enhanced base cost, and (d) a finish coat applied to the enhanced base coat in which the meshes are embedded. The enhanced base coat for the exterior insulation finishing system (EIFS) of the present invention is enhanced by the inclusion a bird repellent dispersed throughout a base material. A preferred bird repellent for use in the enhanced base coat and in the EIFS claddings of the present invention is methyl anthranilate. The finish coat may also include a bird repellent dispersed therein.

A method of installing an enhanced EIFS cladding to a structure having an exterior substrate includes the steps of mounting insulation board to the exterior substrate, applying an enhanced base coat comprising a base material and a bird repellent dispersed therein to the insulation board, embedding a first mesh and optionally a second mesh in the enhanced base coat, and applying a finish coat to the enhanced base coat in which the first and second meshes are embedded. In a further embodiment of the method of the present invention, a bird repellent may be dispersed in the finish coat prior to applying the finish coat to the enhanced based coat.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings, which are incorporated herein and form a part of the specification, illustrate non-limiting embodiments of the present invention, and together with the description, serve to explain the principles of the invention. In the drawings:

FIG. 1 is a representation of the layers of a conventional EIFS structure;

FIG. 2 is a representation of the layers of an embodiment of an enhanced EIFS structure of the present invention;

FIG. 3 is a representation of the layers of another embodiment of an enhanced EIFS structure of the present invention; and

FIG. 4 is a representation of the layers of a further embodiment of an enhanced EIFS structure of the present invention.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

An enhanced exterior insulation finishing system (EIFS) 20 of the present invention is shown in FIG. 2 and includes an adhesive 22, insulation board 23, an enhanced base coat 25, first and second meshes 26′ and 26″, and a finish coat 27. The enhanced base coat 25 includes a bird repellent 101 dispersed throughout a base material 102. The most preferred bird repellent 101 comprises methyl anthranilate. The most preferred base material 102 comprises a polymer-based product mixed with Portland Cement. The enhanced base coat contains sufficient bird repellent to repel a bird penetrating the finish coat. It is expected that the enhanced base coat will contain from 0.1 to 1 g of methyl anthranilate per square foot of EIFS structure. More preferably, it is expected that the enhanced base coat will contain from 0.13 to 0.32 g of methyl anthranilate per square foot of EIFS structure, with most preferably, 0.3 g of methyl anthranilate distributed in the enhanced base coat over each square foot of EIFS structure.

According to another embodiment of the present invention shown in FIG. 3, an EIFS system 33 includes adhesive 22, insulation board 23, enhanced base coat 25, first and second meshes 26′ and 26″, and a finish coat 30. Not only does enhanced base coat 25 include bird repellent 101 dispersed throughout base material 102, finish coat 30 contains a finish material 32 to which has been applied bird repellent 31. In this embodiment, bird repellent 31 has been sprayed onto the finish material 32 after it has been applied, so that bird repellent 31 may only cover the surface of finish material 32 or may only partially disperse into finish material 32.

According to yet another embodiment of the present invention shown in FIG. 4, an EIFS 43 system includes adhesive 22, insulation board 23, enhanced base coat 25, first and second meshes 26′ and 26″, and a finish coat 40. Not only does enhanced base coat 26 includes bird repellent 101 dispersed throughout base material 102, finish coat 40 contains a finish material 42 in which has been dispersed bird repellent 41 prior to application of finish coat 40 to enmeshed, enhanced base coat 25.

A method of installing an enhanced EIFS cladding to a structure to an exterior substrate of the structure according to the present invention involves first applying an adhesive to the exterior substrate with a trowel or, alternatively, to an interior surface of an insulation board having an opposing exterior surface. The insulation board is then mounted to the substrate, with the adhesive sandwiched between the interior surface of the insulation board and the exterior substrate. An enhanced base of the present invention comprising a base material and a bird repellent dispersed therein is then applied to the exterior surface of the insulation board. A first mesh, preferably a standard or intermediate reinforcing mesh, is embedded in the enhanced base coat, and preferably smoothed over so that none of the first mesh is visible. Thereafter, additional enhanced base material is applied to the enmeshed, enhanced base coat, and a second mesh, most preferably one of an intermediate or strong weight, such as Intermediate 6, Intermediate 12 or Strong 15 Finestone Reinforcing Meshes, is then embedded in the additional enhanced base material, and the layer is then smoothed with a trowel, care being taken that the second mesh is not visible through the enhanced base coat. The enhanced base coat is allowed to completely dry before a finish coat is applied. Although the finish coat may simply be any of the conventional finish coats used with standard EIFS applications, most preferably, the finish coat contains bird repellent dispersed in the finish coat prior to application. Alternatively, after the finish coat is applied, but is preferably still wet, a bird repellent such as methyl anthranilate is sprayed on the finish coat.

In one embodiment of the present invention, a portion of a bird repellent concentrate containing 2.29 lbs. of methyl anthranilate per gallon is mixed with a base coat to form an enhanced base coat. Preferably, the base coat is first created by field mixing a 100% polymer-based product in a 1:1 by weight with Portland cement to product a Primus mixture. Most preferably, 2 ounces of the bird repellent concentrate is mixed with 5 gallons of the Primus mixture to create an enhanced base coat, so that 16.23 grams of methyl anthranilate is present in the 5 gallons of enhanced base coat. The enhanced base coat is then applied in a first layer in which the first mesh is embedded so that approximately 2.5 gallons of enhanced base coat is spread over an area of wall of approximately 50-60 ft². Thereafter, a second layer of enhanced base coat of the remaining 2.5 gallons of enhanced base coat is spread over the first layer of enhanced base coat and the second mesh is embedded therein. With this preferred application rate of the first and second layers over 50-60 ft², approx. 16 grams of methyl anthranilate in the base coats will be distributed over the 50-60 ft² of EIFS wall structure. This preferred application amount may also be expressed as from 0.32 g-0.27 g active ingredient methyl anthranilate in the combined base coats per square foot of EIFS structure.

A minimum amount of methyl anthranilate per 5 gallons of Primus mixture is 1 ounce of the bird repellent concentrate described above, which results in a two layer-coverage as described above of approximately 8 grams of methyl anthranilate over 50-60 ft² of EIFS wall structure. This acceptable minimum application rate may also be expressed as from 0.16 g-0.13 g active ingredient methyl anthranilate per square foot of base coats of the EIFS structure.

Greater amounts of methyl anthranilate per 5 gallons of Primus mixture may also be applied. Acceptable amounts of the bird repellent concentrate described above mixed with the Primus mixture as described above may include up 10 ounces, which will which results in a two layer base coat coverage as described above of approx. 81 grams of methyl anthranilate over 50-60 ft² of EIFS wall structure. This acceptable maximum application rate may also be expressed as from 1.62 g-1.35 g active ingredient methyl anthranilate per square foot of EIFS structure in the base coats.

A more preferred application rate which is greater than the most preferred amount of from 0.32 g-0.27 g active ingredient methyl anthranilate per square foot of EIFS structure is that achieved by mixing 6 ounces of the concentrated bird repellent described above in 5 gallons of Primus mixture, so that the final application rate is from approx. 1 g-0.8 g active ingredient methyl anthranilate in the base coats per square foot of EIFS structure.

After the enhanced base coats are allowed to dry, most preferably, an enhanced surface coat is applied. In one embodiment, 2 ounces of the bird repellent concentrate are added to 5 gallons of a finish coat to produce an enhanced finish coat. The 5 gallons of enhanced finish coat are then applied by trowel or spraying to achieve a finish thickness of from 1/16 to ⅛″ in depth. A preferred coverage area of the enhanced finish coat is from 120 to 165 ft². This is an equivalent distribution in the finish coat of the methyl anthranilate active ingredient of from approx. 135 to approx. 98 mg. per square foot of EIFS structure. While this distribution rate resulting from inclusion of 2 ounces of bird repellent concentrate is most preferred, inclusion of half this amount (i.e., 1 ounces of bird repellent concentrate in 5 gallons of finish coat) and of up to 3 to 5 times this amount (i.e., 6 to 10 ounces of bird repellent concentrate in 5 gallons of finish coat) are also acceptable.

The preferred and acceptable distribution amounts of methyl anthranilate bird repellent in EIFS structures according to the present invention expected to be efficacious in discouraging birds from repeated attack on EIFS structure, such that extensive damage to the EIFS structure from birds pecking nesting holes in the EIFS structure is avoided, are summarized in Table I below:

methyl anthranilate minimum most preferred acceptable maximum acceptable preferred range of range of acceptable amount per amount per amount per amount per amount per square foot square foot square foot square foot square foot base coat* 0.13-0.16 g approx. 0.3 g 0.27-0.32 g 0.1-1 g 1.35-1.62 g finish coat** 50-70 mg approx. 110 mg 98-135 mg 50-200 mg 300-550 mg *The base coat is preferably applied in two layers, each of which has a mesh layer separately embedded in it. Alternatively, the base coat may comprise a single layer with one or two mesh layers embedded therein. In either case, the amount per square foot of methyl anthranilate in the final EIFS structure specified above is distributed throughout the base coat layer(s). **Inclusion of bird repellent in the finish coat is preferred but optional.

Although the particular embodiments described above are described with reference to the preferred base coat which is a poly-based product mixed with Portland cement, in which a bird repellent concentrate is mixed in proportions sufficient to obtain the above coverage rates. Of course other forms of the preferred methyl anthranilate may also be mixed with a base coat to obtain the same proportions. For example, it is contemplated that technical grade, crystalline or powdered methyl anthranilate may be mixed with a base coat, either with a powered or dry base coat or with a wet base coat mixture.

It is further contemplated that as other bird repellents may be substituted for the preferred methyl anthranilate as alternate bird repellent products are developed and/or become commercially available. The effective amount of such bird repellents present in the EIFS base coat(s) is hereby defined as that amount sufficient to cause a bird to stop pecking, drilling or drumming at a location on an EIFS structure once the bird has pecked through to the base coat. Although not required by the present invention, the most preferred bird repellents are those which by virtue of their smell, temporary itchiness induced by the repellent or other temporary irritation to the mouth, nose or throat of bird, cause the bird to stop pecking, drilling or drumming and leave the location. Alternative bird repellent agents expected to have utility when mixed with an EIFS base coat to form an enhanced base coat as described herein are preferably selected from the group consisting of methyl phenyl acetate, ethyl phenyl acetate, orthoamino acetophenone, 2-amino-4,5-dimethyl acetophenone, veratroyl amine and dimethyl anthranilate.

The foregoing description is considered as illustrative only of the principles of the invention. Further, since numerous modifications and changes will be readily apparent to those skilled in the art, it is not desired to limit the invention to the exact construction and process shown as described above. Accordingly, all suitable modifications and equivalents may be resorted to falling within the scope of the invention as defined by the claims that follow.

The words “comprise,” “comprising,” “include,” “including,” and “includes” when used in this specification and in the following claims are intended to specify the presence of stated features, integers, components, or steps, but they do not preclude the presence or addition of one or more other features, integers, components, steps, or groups thereof. 

1. An enhanced base coat for an exterior insulation finishing system (EIFS) comprising an adhesive, insulating boards, the enhanced base coat, a first mesh, and a finish coat, said enhanced base coat comprising a bird repellent dispersed throughout a base material.
 2. The enhanced base coat for an EIFS according to claim 1, wherein the bird repellent comprises methyl anthranilate.
 3. The enhanced base coat for an EIFS according to claim 2, wherein the base material comprises a polymer-based product mixed with Portland Cement.
 4. The enhanced base coat for an EIFS according to claim 2, wherein the enhanced base coat contains 8 g to 81 g of methyl anthranilate to each 5 gallons of base material.
 5. The enhanced base coat for an EIFS according to claim 4, wherein the enhanced base coat contains at least approximately 16 g of methyl anthranilate to each 5 gallons of base material.
 6. The enhanced base coat for an EIFS according to claim 2, wherein the methyl anthranilate is present in the base material in an amount effective to obtain coverage of the methyl anthranilate when the enhanced base material is installed in an EIFS structure of from 0.1 to 1 g per square foot of EIFS structure.
 7. An enhanced EIFS cladding for a substrate comprising: an adhesive; an insulation layer mounted to the substrate with the adhesive; an enhanced base coat comprising a base material and a bird repellent dispersed in the base material; a first mesh embedded in the enhanced base coating; a finish coating.
 8. The enhanced EIFS cladding according to claim 7, wherein the bird repellent comprises methyl anthranilate.
 9. The enhanced EIFS cladding according to claim 8, wherein the base material comprises a polymer-based product mixed with Portland Cement.
 10. The enhanced EIFS cladding according to claim 9, wherein each square foot of EIFS structure contains 0.1 to 1 g of bird methyl anthranilate dispersed in the enhanced base coat.
 11. The enhanced EIFS cladding according to claim 9, further comprising a second mesh embedded in the enhanced base coat.
 12. The enhanced EIFS according to claim 11, wherein the first mesh has a first mesh weight and is positioned adjacent the insulation board and the second mesh is of a second mesh weight which is heavier than the first mesh weight and is positioned over the first mesh so that the first mesh is positioned between the insulation board and the second mesh.
 13. The enhanced EIFS cladding according to claim 7, wherein the bird repellent is dispersed in the finish coat.
 14. The enhanced EIFS cladding according to claim 8, wherein the bird repellent is dispersed in the finish coat.
 15. The enhanced EIFS cladding according to claim 9, wherein the bird repellent is dispersed in the finish coat.
 16. A method of installing an enhanced EIFS cladding to a structure having an exterior substrate, said method comprising: mounting an insulation board to the exterior substrate; applying an enhanced base coat comprising a base material and a bird repellent dispersed therein to the insulation board; embedding a first mesh in the enhanced base coat; applying a finish coat to the enhanced base coat in which the first mesh is embedded.
 17. The method of installing an enhanced EIFS cladding according to claim 16, wherein the bird repellent is dispersed in the finish coat.
 18. The method of installing an enhanced EIFS cladding according to claim 16 wherein a second mesh is embedded in the enhanced base coat.
 19. The method of installing an enhanced EIFS cladding according to claim 18, wherein the steps of applying the enhanced base coat and embedding the first and second meshes comprises: applying the enhanced base coat to an exposed surface of the insulation board; embedding the first mesh in the enhanced based coat; applying additional enhanced base coat; and embedding the second mesh in the additional enhanced base coat, wherein the second mesh is of a weight which is heavier than a weight of the first mesh.
 20. The method of installing an enhanced EIFS cladding according to claim 19, wherein the bird repellent is dispersed in the finish coat.
 21. The method of installing an enhanced EIFS cladding according to claim 19, wherein the bird repellent comprises methyl anthranilate. 